Long-fiber foam composite, automobile door using the long-fiber foam composite, and method for manufacturing the long-fiber foam composite

An automobile door, comprising:

• a long-fiber foam composite including small foam body particles having a binding agent with a foaming agent for expanding said binding agent, and a fiber mixture of long fibers being only partially connected to each other via said small foam body particles for forming a low density nonwoven, at least some of said small foam body particles being disposed in said low density nonwoven in a non-expanded form during a formation of said low density nonwoven, said small foam body particles in said non-expanded form being thereby expanded through one of a reaction with and an activation of said foaming agent of said binding agent disposed in said low density nonwoven, said small foam body particle introduced in said non-expanded form embedding said long fibers nodally at crossing points of said long fibers after having been expanded.

The method according to clam 29, which further comprises:

• enclosing the low density nonwoven in a mold;
• and
• pressurizing the mold to activate the foaming agent.